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Medium Duty Body Builders Manual

Model: K270/K370
For Trucks Produced After March 2012

Body Builders Manual Contents


FIGURES .................................................................................................................................................................. iii TABLES .................................................................................................................................................................. iv SECTION 1 INTRODUCTION .............................................................................................................................. 1-1 SECTION 2 SAFETY & COMPLIANCE
SAFETY SIGNALS 2-1 FEDERAL MOTOR VEHICLE SAFETY STANDARDS COMPLIANCE 2-2 Incomplete Vehicle Certication .................................................................................................... 2-2 Noise and Emissions Requirements ................................................................................................ 2-3

SECTION 3 DIMENSIONS
ABBREVIATIONS 3-1 TURNING RADIUS 3-2 CAB TILT 3-2 OVERALL DIMENSIONS 3-5 Side View - K270............................................................................................................................ 3-5 Side View - K370............................................................................................................................ 3-7 Front and Rear Views K270/K370............................................................................................. 3-9 DETAIL VIEWS 3-12 Left side: Chassis Heights K270 ................................................................................................. 3-12 Right side: Chassis Heights K370 ............................................................................................... 3-13 Components Locations K270 ...................................................................................................... 3-15 Components Locations K370 ...................................................................................................... 3-16 Crossmember Locations K270 .................................................................................................... 3-18 Frame Rail Configurations ............................................................................................................ 3-20 Battery Box, Fuel Tanks and Air Tanks K270/K370 ............................................................... 3-21 DPF & SCR Locations K270/K370 ........................................................................................... 3-22 Reyco 79KB Single Rear Axle ..................................................................................................... 3-23 TIRE DATA.................................................................................................................................. 3-23 FRAME AND CAB RELATED HEIGHTS ................................................................................. 3-23 GROUND CLEARANCES .......................................................................................................... 3-23 PTO Clearances............................................................................................................................. 3-24

SECTION 4 EXHAUST & AFTERTREATMENT


EXHAUST AND AFTERTREATMENT INFORMATION 4-1 General Guidelines for DEF System ............................................................................................... 4-3 Installation Requirements and Dimensions for DEF System .......................................................... 4-3 Measurement Reference Points ....................................................................................................... 4-4 GENERAL EXHAUST INFORMATION 4-6

SECTION 5 FRAME LAYOUTS AND BODY MOUNTING


FRAME LAYOUTS Visual Index .................................................................................................................................... 5-1 Acronyms Index .............................................................................................................................. 5-2 CRITICAL CLEARANCES 5-3 Rear Wheels and Cab ...................................................................................................................... 5-3 Body Mounting Using Brackets ...................................................................................................... 5-4 Frame Sill ........................................................................................................................................ 5-4 Brackets........................................................................................................................................... 5-5 Mounting Holes .............................................................................................................................. 5-5 Frame Drilling ................................................................................................................................. 5-6 Hole Location Guidelines ............................................................................................................... 5-6 BODY MOUNTING USING UBOLTS 5-6 Spacers ............................................................................................................................................ 5-6 REAR BODY MOUNT 5-8 i

Body Builder Manual Contents


SECTION 6 FRAME MODIFICATIONS
FRAME MODIFICATIONS 6-1 Introduction ..................................................................................................................................... 6-1 DRILLING RAILS ......................................................................................................................... 6-1 Location and Hole Pattern............................................................................................................... 6-1 MODIFYING FRAME LENGTH 6-2 Frame Insert .................................................................................................................................... 6-2 Changing Wheelbase....................................................................................................................... 6-3 Crossmembers ................................................................................................................................. 6-4

SECTION 7 ELECTRICAL
ELECTRICAL Introduction ..................................................................................................................................... 7-1 ELECTRICAL CIRCUITS Capacity .......................................................................................................................................... 7-1 Dashboard Identification. ................................................................................................................ 7-2 Data Bus Communication ............................................................................................................... 7-3 REMOVAL AND INSTALLATION Removal and Installation, Switches ................................................................................................ 7-4 Removal and Installation, Dashboard Panels .................................................................................. 7-4

APPENDIX A VEHICLE IDENTIFICATION


VEHICLE IDENTIFICATION NUMBER A-1 VIN Location ................................................................................................................................. A-1 Chassis Number Locations............................................................................................................. A-1 CERTIFICATION LABELS A-2 Components and Weights Label .................................................................................................... A-2 Tire/Rim and Weight Rating Data Label ....................................................................................... A-2 Incomplete Vehicle Certication Label ......................................................................................... A-2 COMPONENT IDENTIFICATION A-3 Engine Identication ...................................................................................................................... A-3 Transmission Identication ............................................................................................................ A-4 Front Axle Identication ................................................................................................................ A-4 Rear Axle Identication ................................................................................................................. A-4

APPENDIX B WEIGHT DISTRIBUTION


INTRODUCTION Abbreviations ................................................................................................................................. B-1 CALCULATIONS B-2 Weight Distribution without Body ................................................................................................. B-2 Weight Distribution with Body ...................................................................................................... B-4 Chassis Weights ............................................................................................................................. B-4 COMPLETE (LOADED) VEHICLE B-7 Weight Distribution Analysis......................................................................................................... B-9 Body Length................................................................................................................................... B-9

ii

Figures
Figure 3-1. Side View K270 W/19.5 Tires Height and Length Measurement .................................................................................... 3-5 Figure 3-2. Side View K370 W/19.5 Tires Height and Length Measurement................................................................................... 3-7 Figure 3-3. Side View K270/K370 W/22.5 Tires Height and Length Measurement ........................................................................ 3-8 Figure 3-4. K270/K370 W/19.5 Tires Front View: Width and Ground Clearance Measurements: inches (mm). .................................... 3-10 Figure 3-4.1. K270/K370 W/22.5 Tires Front View: Width and Ground Clearance Measurements: inches (mm). ................................. 3-10 Figure 3-5. K270 W/19.5 Tires Rear View: Width and Ground Clearance Measurements: inches (mm). ..................................... 3-11 Figure 3-5.1 K370 W/19.5 Tires Rear View: Width and Ground Clearance Measurements: inches (mm). ............................................. 3-11 Figure 3-6. Cab Floor: Side View, Left Side ......................................................................................................................................... 3-12 Figure 3-7. Cab Floor: Side View, Left Side......................................................................................................................................... 3-13 Figure 3 -7.1.1 K270 W/ Air to Oil Transmission Cooler, Battery Box, Fuel Tank, Air Tank, DEF Tank, and Crossmember Location Measured From Front Axle: inches (mm). ............................................................................................................ 3-15 Figure 3-7.1.2 K270 W/ Oil to Water Transmission Cooler, Battery Box, Fuel Tank, Air Tank, DEF Tank, and Crossmember Location Measured From Front Axle: inches (mm). ............................................................................................................ 3-15 Figure 3-7.2.2 K370 W/Oil to Water Cooler and 19.5 Tires, Battery Box, Fuel Tank, Air Tank, DEF Tank, and Crossmember Location Measured From Front Axle: inches (mm). ............................................................................................................ 3-16 Figure 3-7.2.3 K270/K370 22.5 Tires Battery Box, Fuel Tank, Air Tank, DEF Tank, and Crossmember Location Measured From Front Axle: inches (mm). ............................................................................................................................................ 3-17 Figure 3-8.3. K270 Crossmember Location ............................................................................................................................................. 3-18 Figure 3-8.4. K370 Crossmember Locations....................................................................................................................................... 3-19 Figure 3-9. K270/K370 Rail Measurements....................................................................................................................................... 3-20 Figure 3-10. K270/K370 Battery Box, Fuel Tank and Air Tanks Measurement mm (in) ................................................................... 3-21 Figure 3-11. K270/K370 Exhaust Measurements ..................................................................................................................................... 3-22 Figure 4-1: Measurement Location of DEF Supply Module (Pump) ......................................................................................................... 4-4 Figure 4-2: Measurement Location of DEF Dosing Module (Injector) ...................................................................................................... 4-4 Figure 4-3: Orientation of Dosing Module ................................................................................................................................................. 4-5 Figure 4-4: Routing DEF Lines and DEF Trap........................................................................................................................................... 4-5 Figure 4-5: Horizontal Crossover DPF and SCR with Horizontal Tailpipe................................................................................................ 4-6 Figure 4-5.1: Top view of Horizontal Crossover DPF and SCR with Horizontal Tailpipe ........................................................................ 4-6 Figure 4-5.2: Right view of Horizontal Crossover DPF and SCR with Horizontal Tailpipe ...................................................................... 4-7 Figure 4-5.3: Back view of Horizontal Crossover DPF and SCR with Horizontal Tailpipe ...................................................................... 4-7 Figure 5-1: Horizontal Crossover DPF/SCR, LH horizontal tailpipe, RH BOC rectangular fuel tank, RH BOC rectangular DEF tank and LH BOC battery box........................................................................................................................................ 5-2 Figure 5-2. Minimum Clearance Between Top Of Rear Tires And Body Structure Overhang. ................................................................. 5-3 Figure 5-3. Minimum Back of Cab Clearance ....................................................................................................................................... 5-3 Figure 5-4. Spacer Between Frame Sill and Body Rail - Rubber or Plastic ....................................................................................... 5-5 Figure 5-5. High Compression Spring Between the Mounting Bolt and Upper Bracket.................................................................. 5-5 Figure 5-6. Rubber Spacer Between Brackets ....................................................................................................................................... 5-5 Figure 5-7. Hole Locations Guidelines for Frame Rail and Bracket ................................................................................................... 5-5 Figure 5-8. Crossmember-Gusset Hole Pattern Requirements. [inch(mm)] .................................................................................... 5-6 Figure 5-9. Acceptable U-Bolt Mounting with Wood and Fabricated Spacers ................................................................................... 5-7 Figure 5-10. Clearance Space for Air Lines and Cables ..................................................................................................................... 5-7 Figure 5-11 Example of Fishplate Bracket at Rear End of Body, used with U-Bolts......................................................................... 5-8 Figure 6-1. Detail of Frame ........................................................................................................................................................................ 6-2 Figure 6-2. Frame Insert Extension and Joint Welding .............................................................................................................................. 6-2 Figure 6-3 Comparison of Original, Shortened, and Extended Wheelbases. .............................................................................................. 6-4 Figure 6-4. Crossmember Added When Distance Exceeds 60 Inches (1524 mm) ......................................................................... 6-4 Figure 7-1. Instrument Layout .................................................................................................................................................................... 7-2 Figure 7-2. Data Bus Communication Architecture ................................................................................................................................... 7-3 Figure A-2. Drivers Door and Door Frame Label ................................................................................................................................ A-2 Figure A-3. Engine Identication Location ......................................................................................................................................... A-3 Figure A-4. Front Axle Identication .................................................................................................................................................... A-4 Figure A-5. Rear Axle Identication ..................................................................................................................................................... A-4 Figure B-1. Balanced Load: CGf 100 in. from front axle ....................................................................................................................B-2 Figure B-2. Unbalanced Load: CGf 133 In. From Front Axle ............................................................................................................B-3 Figure B-3. Balanced Body Unloaded: CGf 184.7 in. (4691.45 mm) from front axle. .....................................................................B-5 Figure B-4. Liftgate Example: CGf 322.2 in (8183.9 mm) from front axle. .......................................................................................B-5

iii

Tables

Table 3-1. Abbreviations Used............................................................................................................................................................... 3-1 Table 3-2 Turning Radius ........................................................................................................................................................................... 3-2 Table 3-3 Cab Tilt Height........................................................................................................................................................................... 3-3 Table 3-4. Overall K270 W/19.5 Tires Dimensions inches (mm) .............................................................................................................. 3-6 Table 3-5.1. Overall K370 W/19.5 Tires Dimensions .................................................................................................................................. 3-7 Table 3-5.2. K270/K370 W/22.5 Tires Overall Dimensions ...................................................................................................................... 3-8 Table 3-6 K270 W19.5 Tires Battery Box Step and Cab Floor Measurements ........................................................................................ 3-12 Table 3-7 Battery Box Step and Cab Floor Measurements ..................................................................................................................... 3-13 Table 3-8 Floor to Frame Measurements.................................................................................................................................................. 3-14 Table 3-9.1. K270 Crossmember Location Measured From the Front of the Frame inches (mm) ......................................................... 3-18 Table 3-9.2 K370 Crossmember Location Measured From Front Axle Centerline inches (mm) ........................................................ 3-19 Table 3-10. Frame Rail Strength Characteristics ...................................................................................................................................... 3-20 Table 3-11. K270/K370 Exhaust Location Measured From BOC inches (mm) ....................................................................................... 3-22 Table 3-12. K270 / K370 Exhaust Location Measured From BOC inches (mm) ..................................................................................... 3-22 Table 5-1 Symbols...................................................................................................................................................................................... 5-1 Table 7-1. Additional Spare Circuits for Wiring ...................................................................................................................................... 7-23 Table A-1. Model Year (Code) Designations. ...................................................................................................................................... A-1 Table B-1. K270/K370 Single Rear Axle Bare Chassis Tare Weights (no driver, no fuel) ................................................................. B-4 Table B-2. K270 Weight Distribution and Chassis Rating Calculation (sample ........................................................................................ B-7 Table B-2.1. K370 Weight Distribution and Chassis Rating Calculation (sample) .................................................................................... B-8 Table B-3. Available K270/K370 Body Lengths ............................................................................................................................. B-10

iv

Section 1 Introduction

This manual provides body builders with appropriate information and guidelines useful in the body planning and installation process. This information will be helpful when installing bodies or other associated equipment. This manual contains appropriate dimensional information, guidelines for mounting bodies, guidelines for modifying frames, electrical wiring information, and other information useful in the body installation process. The intended primary users of this manual are body builders who install bodies and associated equipment on K270/K370 Medium Duty vehicles. Dealers who sell and service the vehicle will also nd this information useful. This Body Builders Manual can be very useful when specifying a vehicle, particularly when the body builder is involved in the vehicle denition and ordering process. Early in the process, professional body builders can often contribute valuable information that reduces the ultimate cost of the body installation. This manual is not a maintenance manual or an operation manual. For chassis maintenance and repair information consult the PACCAR ServiceNet available in the Service Department of the selling dealer or order a custom shop manual or parts catalog for your vehicle through your local dealer. For chassis operating information consult the Operators Manual, included with each vehicle. It can also be ordered from your local dealer.

1-1

Section 2 Safety & Compliance


SAFETY SIGNALS
We have put a number of alerting messages in this book. Please read and follow them. They are there for your protection and information. These alerting messages can help you avoid injury to yourself or others and help prevent costly damage to the vehicle. Key symbols and signal words are used to indicate what kind of message is going to follow. Pay special attention to comments prefaced by WARNING, CAUTION, and NOTE. Please do not ignore any of these alerts.

Warnings, Cautions, and Notes WARNING:


When you see this word and symbol, the message that follows is especially vital. It signals a potentially hazardous situation which, if not avoided, could result in death or serious injury. This message will tell you what the hazard is, what can happen if you dont heed the warning, and how to avoid it.

Example: WARNING! Be sure to use a circuit breaker designed to meet liftgate amperage requirements. An incorrectly specied circuit breaker could result in an electrical overload or re situation. Follow the liftgate installation instructions and use a circuit breaker with the recommended capacity.

CAUTION:

Signals a potentially hazardous situation which, if not avoided, could result in minor or moderate injury or damage to the vehicle.

Example: CAUTION: Never use a torch to make a hole in the rail. Use the appropriate drill bit.

NOTE:
Provides general information. F or example, the note could warn you on how to avoid damaging your vehicle or how to drive the vehicle more efciently. Example: Note: Be sure to provide maintenance access to the battery box and fuel tank ll neck.

Please take the time to read these messages when you see them, and remember:
WARNING Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION Signals a potentially hazardous situation which, if not avoided, could result in minor or moderate injury or damage to the vehicle. NOTE Useful information that is related to the topic being discussed.

2-1

Section 2 Safety & Compliance


FEDERAL MOTOR VEHICLE SAFETY STANDARDS COMPLIANCE
As an Original Equipment Manufacturer (OEM), Kenworth Truck Co. ensures that our products comply with all applicable U.S. or Canadian Federal Motor Vehicle Safety Standards. However, the fact that this vehicle has no fth wheel and that a Body Builder (Intermediate or Final Stage Manufacturer) will be doing additional modications means that the vehicle was incomplete when it left the build plant. See next section and Appendix A for additional information.

Incomplete Vehicle Certication

An Incomplete Vehicle Document is shipped with the vehicle, certifying that the vehicle is not complete. See Figure 21. In addition, afxed to the drivers side door frame or edge is an Incomplete Vehicle Certication label. See Figure 22. For further information on Vehicle Certication and Identication, see APPENDIX A VEHICLE IDENTIFICATION.

NOTE:

These documents list the U.S. or Canadian Federal Motor Vehicle Safety Standard regulations that the vehicle complied with when it left the build plant. You should be aware that if you add, modify or alter any of the components or systems covered by these regulations, it is your responsibility as the Intermediate or Final Stage Manufacturer to ensure that the complete vehicle is in compliance with the particular regulations upon completion of the modications.
U.S. EPA Noise Label (U.S. registered vehicles only) Tire, Rim and Weight Rating Data label Final Stage Manufacturer Label to be Installed by Final Stage Manufacturer

Chassis Serial Number

Safety Mark (Canadian Registry Only)

Major Components and Weights Label

Incomplete Vehicle Cer tication Label Figure 2-1. Incomplete Vehicle Cer tication Document

Figure 2-2. Locations of Cer tication Labels - Drivers Door and Frame

As the Intermediate or Final Stage Manufacturer, you should retain the Incomplete Vehicle Document for your records. In addition, you should record and retain the manufacturer and serial number of the tires on the vehicle. Upon completion of the vehicle (installation of the body and any other modications), you should afx your certication label to the vehicle as required by Federal law. This tag identies you as the Intermediate or Final Stage Manufacturer and certies that the vehicle complies with Federal Motor Vehicle Safety Standards. (See Figure 22.) For Canadian nal stage manufacturers see:

http://www.gazette.gc.ca/index-eng.html and http://www.tc.gc.ca/eng/acts-regulations/menu.htm for the regulations.


Or contact: Transport Canada Tower C, Place de Ville, 330 Sparks Street Ottawa, Ontario K1A 0N5 (613) 990-2309 TTY: 1-888-675-6863

2-2

Section 2 Safety & Compliance


Noise and Emissions Requirements NOTE:
This truck may be equipped with a converter mufer unit in order to meet both noise and exhaust emissions requirements. Removal or tampering with the converter mufer will not improve engine performance. Also tampering is against the rules that are established by the U.S. Code of Federal Regulations and Environment Canada Regulations. The converter mufer may only be replaced with an approved part. Relocation of converter mufer will affect noise and emission performance. Contact the engine manufacturer for any requirements and restrictions prior to any modications. In particular, there are requirements and restrictions for exhaust pipe materials and for maximum exhaust system lengths from turbo outlet to mufer inlet.

NOTE:

2-3

S e c ABBREVIATIONS Throughout this section and in other sections as well, abbreviations are t used to describe certain characteristics on your vehicle. The chart below lists the abbreviated terms used. i Table 3-1. Abbreviations Used o A OVERALL VEHICLE LENGTH n
AF B CA D WB HA FAX EOF CA AE TL FRAME RAIL OVERHANG LENGTH BEHIND REAR AXLES FRONT BUMPER TO FRONT AXLE LENGTH BACK OF CAB TO REAR AXLE LENGTH CAB HEIGHT WHEELBASE LENGTH HEIGHT AXLE FRONT AXLE END OF FRAME CAB TO AXLE AXLE TO END TOTAL LENGTH

Section 3 Dimensions

3 D i m e n s i o n s

3-1

Section 3 Dimensions

TURNING RADIUS

Approximate turning radius specications for the K270/K370 are listed (by wheelbase) in the following tables. Tables 3-2 and 3-3 list turn radius information for chassis with standard components. Optional components may give different results.

Table 3-2 Turning Radius

Model

Rear Axles

Tires, Bridgestone

Wheelbase Range mm 3606.8 3911.6 4216.4 4521.2 Inch 142 154 166 178 190 202 214 226 238 166 178 190 202 214 146 158 170 182 194 206 218 230 242

Curb to Curb Est. Radius ft 15.12 16.40 17.68 18.95 20.23 21.51 22.79 24.07 25.34 18.06 19.36 20.67 21.98 23.28 15.88 17.19 18.49 19.80 21.11 22.41 23.72 25.02 26.33 m 4.6 5.0 5.4 5.8 6.2 6.6 6.9 7.3 7.7 5.5 5.9 6.3 6.7 7.1 4.8 5.2 5.6 6.0 6.4 6.8 7.2 7.6 8.0

Wall to Wall Radius Est. ft 19.12 20.40 21.68 22.95 24.23 25.51 26.79 28.07 29.34 22.06 23.36 24.67 25.98 27.28 19.88 21.19 22.49 23.80 25.11 26.41 27.72 29.02 30.33 m 5.8 6.2 6.6 7.0 7.4 7.8 8.2 8.6 8.9 6.7 7.1 7.5 7.9 8.3 6.1 6.5 6.9 7.3 7.7 8.1 8.4 8.8 9.2

K270 W/19.5 Tires

Single

R250F 245/70R19.5

4826 5130.8 5435.6 5740.4 6045.2 4216.4 4521.2

K370 W/19.5 Tires

Single

R250F 285/70R19.5

4826 5130.8 5435.6 3708.4 4013.2

K270/K370 W/22.5 tires

Single

R250F 11R22.5 14PR or R250ED 275/70R22.5 18PLY

4318 4622.8 4927.6 5232.4 5537.2 5842 6146.8

3-2

Section 3 Dimensions
CAB TILT K270 W/19.5 Tires

S e c t i o n 3 D i m e n s i o n s

Table 3-3 Cab Tilt Height CAB Tilt K270 W/19.5 Tires K370 W/19.5 Tires K270/K370 W/22.5 Tires Highest point mm (in)

K370 W/19.5 Tires

3217.5 (126.5)

3260.5 (128)

3336.9 (131)

3-3

Section 3 Dimensions
K270/K370 W/22.5 Tires

3-4

S e c t OVERALL DIMENSIONS i This section includes drawings and charts of the base model K270/K370 vehicle, which includes K370 rear and front suspension o M725 and M711 11R22.5 14PR 41.9 tires, a R227F R250F 245/70R19.5, M729F 245/70R19.5 K270, 14PLY 295/75R22.5 285/70R19.5 and M729F 285/70R19.5 K370 tires. Use these drawings to plan overall vehicle configurations. n
On the pages that follow, detail drawings show particular views of each component of the vehicle. They illustrate important measurements critical to designing bodies of all types. See the Contents at the beginning of the manual to locate the drawing you need.

Section 3 Dimensions

Side View - K270

3 D i m e n s i o n s

Figure 3-1. Side View K270 W/19.5 Tires Height and Length Measurement

3-5

Section 3 Dimensions

Table 3-4. Overall K270 W/19.5 Tires Dimensions inches (mm)


Model WB mm (in) 3606.8 (142) 3911.6 (154) 4216.4 (166) K270 W/19.5 Tires 4521 (178) 4826 (190) 5130.8 (202) 5435.6 (214) 5740.4 (226) 6045.2 (238) FAX to BOC mm (in) 338.8 (13.3) 338.8 (13.3) 338.8 (13.3) 338.8 (13.3) 338.8 (13.3) 338.8 (13.3) 338.8 (13.3) 338.8 (13.3) 338.8 (13.3) FAX to Back of Intake mm (in) 431.8 (17) 431.8 (17) 431.8 (17) 431.8 (17) 431.8 (17) 431.8 (17) 431.8 (17) 431.8 (17) 431.8 (17) Overhang mm(in) 1828.8 (72) 1828.8 (72) 1828.8 (72) 2133.6 (84) 2438.4 (96) 2743.2 (108) 3048 (120) 3048 (120) 3048 (120) Frame Length mm(in) 6630.6 (261) 6935.4 (273) 7240.2 (285) 7849.8 (309) 8459.4 (333) 9069 (357) 9678.6 (381) 9983.4 (393) 10288.2 (405) Overall Length mm(in) 6710.6 (264) 7015.4 (276) 7320.2 (288) 7929.8 (312) 8539.4 (336) 9149 (360) 9758.6 (384) 10063.4 (396) 10368.2 (408) *CA mm(in) 3041.8 (120) 3346.6 (132) 3651.4 (144) 3956.2 (156) 4261 (168) 4565.8 (180) 4870.6 (192) 5175.4 (204) 5480.2 (216) Recommended Body Length ft 16 17 18 20 22 24 26 27 28

*Consider a usable CA= CA Dimension - 6 High air intake 4 Clearance.

3-6

Section 3 Dimensions
Side View - K370

S e c t i o n

3 D i m e n s i o Figure 3-2. Side View K370 W/19.5 Tires Height and Length Measurement n Table 3-5.1. Overall K370 W/19.5 Tires Dimensions s
WB mm (in) FAX to BOC mm (in) 288.8 (11.4) 288.8 (11.4) 288.8 (11.4) 288.8 (11.4) 288.8 (11.4) FAX to Back of Intake mm (in) 381.0 (15) 381.0 (15) 381.0 (15) 381.0 (15) 381.0 (15) Overhang mm(in) 1828.8 (72) 2133.6 (84) 2438.4 (96) 2743.2 (108) 3048 (120) Frame Length mm(in) 7290.2 (287) 7899.8 (311) 8509.4 (335) 9119 (359) 9728.6 (383) Overall Length mm(in) 7370.2 (290) 7979.8 (314) 8589.4 (338) 9199 (362) 9808.6 (386) *CA mm(in) Recommended Body Length ft 18 20 22 24 26

K370 W/19.5 Tires

4216.4 (166) 4521 (178) 4826 (190) 5130.8 (202) 5435.6 (214)

3676.4 (144.7) 3981.2 (156.7) 4286 (168.7) 4590.8 (180.7) 4895.6 (192.7)

*Consider a usable CA= CA Dimension - 6 High air intake 4 Clearance.

3-7

Section 3 Dimensions

Figure 3-3. Side View K270/K370 W/22.5 Tires Height and Length Measurement Table 3-5.2. K270/K370 W/22.5 Tires Overall Dimensions
WB mm (in) 3708.4 (146) 4013.2 (158) 4318 (170) 4622.8 (182) 4927.6 (194) 5232.4 (206) 5537.2 (218) 5842 (230) 6146.8 (242) FAX to BOC mm (in) 288.8 (11.4) 288.8 (11.4) 288.8 (11.4) 288.8 (11.4) 288.8 (11.4) 288.8 (11.4) 288.8 (11.4) 288.8 (11.4) 288.8 (11.4) FAX to Back of Intake mm (in) 1039.9 (40.9) 1039.9 (40.9) 1039.9 (40.9) 1039.9 (40.9) 1039.9 (40.9) 1039.9 (40.9) 1039.9 (40.9) 1039.9 (40.9) 1039.9 (40.9) Overhang mm(in) 1828.8 (72) 1828.8 (72) 1828.8 (72) 2133.6 (84) 2438.4 (96) 2743.2 (108) 3048 (120) 3048 (120) 3048 (120) Frame Length mm(in) 6782.2 (267) 7087 (279) 7391.8 (291) 8001.4 (315) 8611 (339) 9220.6 (363) 9830 (387) 10135 (399) 10439.9 (411) Overall Length mm(in) 6862.2 (270) 7167 (282.2) 7471.8 (294) 8081.4 (318) 8691 (342) 9300.6 (366) 9910.2 (390) 10215 (402) 10519.8 (414) Recommended Body Length ft 16 17 18 20 22 24 26 27 28

Model

*CA mm(in) 3421.38 (134.7) 3726.18 (146.7) 4030.98 (158.7) 4335.78 (170.7) 4640.58 (182.7) 4945.38 (194.7) 5250.18 (206.7) 5554.98 (218.7) 5859.78 (230.7)

K270/K370 W/22.5 Tires

*Consider a usable CA= CA Dimension -6 High air intake 4 Clearance 4 Interface duct.

3-8

Section 3 Dimensions

Front and Rear Views K270/K370


inches (mm)

3-9

Section 3 Dimensions
Front and Rear Views K270/K370 K270

K370

Figure 3-4. K270/K370 W/19.5 Tires Front View: Width and Ground Clearance Measurements: inches (mm).

Figure 3-4.1. K270/K370 W/22.5 Tires Front View: Width and Ground Clearance Measurements: inches (mm). 3-10

S e c t Front and Rear Views K270/K370 W/19.5iand 22.5 Tires o n 3 D i m e n s i o n s


Figure 3-5. K270 W/19.5 Tires Rear View: Width and Ground Clearance Measurements: inches (mm).

Section 3 Dimensions

Figure 3-5.1 K370 W/19.5 Tires Rear View: Width and Ground Clearance Measurements: inches (mm).
Note: 11R22.5 is 10.3" (261.6mm) and 295/75R22.5 is 9.8" (248.9mm)

3-11

Section 3 Dimensions
.

DETAIL VIEWS Left side: Chassis Heights K270 W/19.5 Tires

Figure 3-6. Cab Floor: Side View, Left Side Table 3-6 K270 W19.5 Tires Battery Box Step and Cab Floor Measurements

K270 19.5 Tires

Position
In

Unladen
mm 258 546 854.3 In 8 19 31.2 10.1 21.4 33.6

Laden
mm 205.2 483.6 793.4

A FUEL SUPPORT STEP B FIRST STEP C SECOND STEP FLOOR

3-12

S e c Detail Views t Right side: Chassis Heights K270/K370 W/22.5 Tires i o n 3 D i m e n s i o n s


Figure 3-7. Cab Floor: Side View, Left Side Table 3-7 Battery Box Step and Cab Floor Measurements

Section 3 Dimensions

K370 19.5 Tires

K270/K370 22.5 Tires


Unladen
In 13.5 17.5 29.5 37.3 mm 342.9 444.4 749.3 947.4 In 10.5 14.1 26 33.8

Position
A FUEL SUPPORT
STEP

Unladen
In 10.5 14.5 26.5 34.3 mm 269 369.4 673.7 872.6

Laden
In 7.5 11.1 23 30.8 mm 191.2 281.9 585.9 784

Laden
mm 266.7 358.1 660.4 858.5

B FIRST STEP C SECOND STEP


FLOOR

D CABFLOOR

3-13

Section 3 Dimensions

Table 3-8 Floor to Frame Measurements.

Frame Heights K270 W/19.5 Tires K370 W/19.5 Tires K270/K370 W/22.5 Tires

LOADED inches (mm) Front Axle Rear Axle 32.11 (815.3) 32.65 (829.3) 35.65 (905.5) 32.2 (817.3) 33.3 (846.3) 36.3 (922.0)

UNLOADED inches (mm) Front Axle Rear Axle 34.47 (875.5) 36.08 (916.4) 39.08 (992.6) 34.5 (876.1) 35.6 (905.4) 38.6 (980.4)

3-14

Section 3 Dimensions
Detail Views Components Locations K270 W/19.5 Tires

Figure 3 -7.1.1 K270 W/ Air to Oil Transmission Cooler, Battery Box, Fuel Tank, Air Tank, DEF Tank, and Crossmember Location Measured From Front Axle: inches (mm).

Figure 3-7.1.2 K270 W/ Oil to Water Transmission Cooler, Battery Box, Fuel Tank, Air Tank, DEF Tank, and Crossmember Location Measured From Front Axle: inches (mm). 3-15

Section 3 Dimensions
Detail Views Components Locations K370

Figure 3-7.2.1 K370 W/Air to Oil Transmission Cooler, 19.5 tires Battery Box, Fuel Tank, Air Tank, DEF Tank and Crossmember Location Measured From Front Axle: inches (mm).
*

Figure 3-7.2.2 K370 W/Oil to Water Transmission Oil Cooler and 19.5 Tires, Battery Box, Fuel Tank, Air Tank, DEF Tank, and Crossmember Location Measured From Front Axle: inches (mm). 3-16

Section 3 Dimensions

Figure 3-7.2.3 K270/K370 22.5 Tires, Battery Box, Fuel Tank, Air Tank, DEF Tank, and Crossmember Location Measured From Front Axle: inches (mm).

3-17

Section 3 Dimensions
Detail Views Crossmember Locations K270 W/19.5 Tires

Figure 3-8.3. K270 Crossmember Location Table 3-9.1. K270 Crossmember Location Measured From the Front of the Frame inches (mm)

Model

WB mm (in)
3606.8 (142) 3911.6 (154) 4216.4 (166)

BOC C/M mm(in)


2064.4 (81.3) 2064.4 (81.3) 2064.4 (81.3) 2064.4 (81.3) 2064.4 (81.3) 2064.4 (81.3) 2064.4 (81.3) 2064.4 (81.3) 2064.4 (81.3)

1st Intermediate C/M mm(in)


3183.4 (125) 3183.4 (125) 3183.4 (125) 3183.4 (125) 3183.4 (125) 3183.4 (125) 3183.4 (125) 3183.4 (125) 3183.4 (125)

1st Midship C/M mm(in)


3603.4 (142) 3603.4 (142) 3603.4 (142) 3603.4 (142) 3603.4 (142) 3603.4 (142) 3603.4 (142) 3603.4 (142) 3603.4 (142)

2nd Intermediate C/M mm(in)


Does Not Apply Does Not Apply Does Not Apply Does Not Apply 4397 (173) Does Not Apply Does Not Apply Does Not Apply Does Not Apply

2nd Midship C/M mm(in)


Does Not Apply Does Not Apply Does Not Apply Does Not Apply Does Not Apply 4663 (183.5) 4700 (185) 4700 (185) 5025 (198)

Front susp C/M mm(in)


4073.7 (160) 4378.5 (172) 4683.3 (184) 3894.7 (153) 4199.5 (165) 5597.7 (220) 5902.5 (232) 6207.3 (244) 6512.1 (156)

Rear susp C/M mm(in)


5353.2 (211) 5658 (223) 5962.8 (235) 5132 (202) 5436.8 (214) 6877.2 (271) 7182 (283) 7486.8 (295) 7791.6 (307)

2nd Fill in C/M mm(in)


Does Not Apply Does Not Apply Does Not Apply Does Not Apply 7468 (294) 7925.2 (312) 8382.4 (330) 8687.2 (342) 8992 (354)

K270 W/19.5 Tires

4521 (178) 4826 (190) 5130.8 (202) 5435.6 (214) 5740.4 (226) 6045.2 (238)

3-18

Section 3 Dimensions
Detail Views Crossmember Locations K370

Figure 3-8.4. K370 Crossmember Locations

Table 3-9.2 K370 Crossmember Location Measured From Front Axle Centerline inches (mm)
K370 W/19.5 Tires WB 166 WB 178 WB 190 WB 202 WB 214

BOC C/M 46.6 (1185) 46.6 (1185) 46.6 (1185) 46.6 (1185) 46.6 (1185)

1st C/M 92.9 (2358.4) 92.9 (2358.4) 92.9 (2358.4) 92.9 (2358.4) 92.9 (2358.4)

2nd C/M Does Not Apply 173.1 (4397) 173.1 (4397) 173.1 (4397) 140.1 (3558)

Front susp C/M 141.3 (3589.9) 153.3 (3894.7) 165.3 (4199.5) 177.3 (4504.3) 189.3 (4809.1)

Rear susp C/M 190 (4827.2) 202 (5132) 214 (5436.8) 226 (5741.6) 238 (6046.5)

1st Rear C/M Does Not Apply Does Not Apply 252.5 (6413) 270.5 (6870.2) 288.5 (7327.4)

Model

WB mm (in)
3708.4 (146) 4013.2 (158) 4318 (170)

BOC C/M mm(in)


1185 (46.6) 1185 (46.6) 1185 (46.6) 1185 (46.6) 1185 (46.6) 1185 (46.6) 1185 (46.6) 1185 (46.6) 1185 (46.6)

1st Intermediate C/M mm(in)


Does Not Apply Does Not Apply Does Not Apply 4257 (167.5) Does Not Apply Does Not Apply Does Not Apply 5503 (216.5) 5815 (229)

1st Midship C/M mm(in)


3463.4 (136) 3463.4 (136) 3463.4 (136) 3463.4 (136) 3463.4 (136) 3463.4 (136) 3463.4 (136) 3463.4 (136) 3463.4 (136)

2nd Intermediate C/M mm(in)


Does Not Apply Does Not Apply Does Not Apply Does Not Apply Does Not Apply Does Not Apply Does Not Apply Does Not Apply Does Not Apply

2nd Midship C/M mm(in)


Does Not Apply Does Not Apply Does Not Apply Does Not Apply 4257 (167.5) 4257 (167.5) 4663 (183.5) 4663 (183.5) 4875 (192)

Front susp C/M mm(in)


3081.9 3386.7 3691.5 3996.3 4301.1 4605.9 4910.7 5215.5 5520.3

Rear susp C/M mm(in)


4319.2 4624 4928.8 5233.6 5538.4 5843.2 6148 6452.8 6757.6

2nd Fill in C/M


Does Not Apply Does Not Apply Does Not Apply 7180.4 (282.5) 7619.6 (300) 8076.8 (318) 8483.2 (334) 8781 (346) 9085.8 (358)

K270/ K370 W/22.5 Tires

4622.8 (182) 4927.6 (194) 5232.4 (206) 5537.2 (218) 5842 (230) 6146.8 (242)

3-19

Section 3 Dimensions
Frame Rail Configurations

K270 9-7/8 STEEL RAIL

K370 10-1/4 STEEL RAIL

Figure 3-9. K270/K370 Rail Measurements

Table 3-10. Frame Rail Strength Characteristics


RAIL STRENGTH 10.25 Rail (K270 W22.5 tires and K370 W19.5 and 22.5 tires) 120,000
3

9.875 Rail (K270 W19.5 tires) 120,000 10.45 1,254,404

Yield Strength, PSI Section Modulus, in RBM, Lbs-Inch

11.65 1,398,664

3-20

Section 3 Dimensions

Battery Box, Fuel Tanks and Air Tanks K270/K370

Figure 3-10. K270/K370 Battery Box, Fuel Tank and Air Tanks Measurement mm (in)

3-21

Section 3 Dimensions

Detail Views DPF & SCR Locations K270/K370

Figure 3-11. K270/K370 Exhaust Measurements Table 3-11. K270/K370 Exhaust Location Measured From BOC inches (mm)
Model K270 K370 A 29.6 (751.4) 40.8 (1036.4) B 64.8 (1645.3) 76 (1930.3) C 30.7 (780.7) 42 (1065.7) D 78.8 (2002) 90.1 (2287.3) E 16.5 (420) 16.5 (420) F 14.6 (370.4) 14.6 (370.4)

Table 3-12. K270 / K370 Exhaust Location Measured From BOC inches (mm)
Model K270 K370 A 5.7 (145) 5.7 (145) B 5.3 (134) 5.3 (134) C 9.9 (250.8) 10.2 (260) D 12.6 (320.4) 12.6 (320.4) E 16.5 (420.2) 16.5 (420.2) F 12 (304.2) 12 (304.2) G 14 (354.2) 14 (354.2)

3-22

Section 3 Dimensions
Reyco 79KB Single Rear Axle Hendrickson HAS Single Rear Axle

Suspension Reyco 79KB Single Hendrickson HAS 210L

Rating Laden Ride Height 21K 6.6" 23K 8.3"

Unladen Ride Height 9.0" 8.5"

TIRE DATA
For dimensions of your particular Bridgestone tire, visit the Bridgestone website, www.bridgestonetrucktires.com

FRAME AND CAB RELATED HEIGHTS


The bottom of the frame rail (BOF) at the front and rear axle can be used as a reference point to estimate vertical heights. Use the following to calculate estimates for frame and cab related heights, such as top of frame rail, step height, top of exhaust pipe, etc.: 1.) Tire radius data from the manufacturer 2.) Front and rear suspension ride heights in this section 3.) Frame rail heights defined in this section if needed 4.) Component dimensions from bottom of rail defined in this section if needed Note that there are many factors that will affect heights including, but not limited to, front and rear axle loading and tire pressure. Placement of frame components such as fuel tanks will affect loads on the front axle and rear axle, as well as distribution to the left and right sides of the vehicle. Heights calculated from this information are estimates only.

GROUND CLEARANCES
To calculate estimates for ground clearance for mounted components using the underside of the bottom of the frame rail as a reference use the following: 1.) Tire radius data from the manufacturer 2.) Front and rear suspension ride heights in this section 3.) Component dimensions from bottom of rail defined in this section Ground clearances, like height calculations, are affected by factors including, but not limited to, front and rear axle loading and tire pressure. Placement of frame components, such as fuel tanks, will affect loads on the front axle and rear axle, as well as distribution to the left and right side of the vehicle. Ground clearances calculated from this information are estimates only.

3-23

Section 3 Dimensions
PTO Clearances
The following visuals are provided to help or aid in determining PTO locations and clearances. For specific dimensions please work through your local Kenworth dealer. Multiple PTOs are shown for layout purposes only. Power equipment, i.e., drive shafts & power pumps are not included. Body builders should select the appropriate Chelsea or Muncie 24V electric over air PTOs for their application and customer requirements. NOTE: All installations are only RH side PTO locations shown below are for reference only. In order to ensure the PTO area remains clear of air equipment, electrical and emissions equipment, Kenworth recommends always ordering PTO controls, even when installing the PTO aftermarket. Contact your local dealer for assistance. Automatic Transmission Allison 2000:

3-24

Section 4 Exhaust & Aftertreatment


EXHAUST AND AFTERTREATMENT INFORMATION
The following section is designed to give you information regarding the exhaust and after-treatment systems on Kenworth chassis. All Kenworths equipped with 2010 emission level engines will utilize Selective Catalyst Reduction (SCR). SCR is a process in which Diesel Exhaust Fluid (DEF) is injected into the exhaust down stream of the engine. DEF is converted to ammonia by the heat of the exhaust system. Inside of the SCR canister, a catalyst causes a chemical reaction between the ammonia and NOx, turning it into water and nitrogen. For more information on the specific details of how SCR works, please contact your local Kenworth dealer. On most Kenworth chassis, the DEF Supply Module (or pump) is integrated into the DEF tank. Kenworth does not allow relocation of this pump. The following schematic details how the DEF lines route to the after-treatment system.

4-1

Section 4 Exhaust & Aftertreatment


DEF will freeze at approximately 11 F (-12 C). In order to keep DEF from freezing, all tanks will be heated with engine coolant. The following schematic shows the routing of these lines. The coolant lines that run to and from the SCR system must not be tampered with, or used for a source of heat and/or cooling for other components on the chassis. It is critical that the system is not compromised in any manner.

4-2

Section 4 Exhaust & Aftertreatment


General Guidelines for DEF System
The installation of the DEF tank is a critical component of the SCR system. While Kenworth does not recommend relocating the DEF tank, there are applications and body installations that will require it. The guidelines below must be strictly followed by any entity relocating the tank. Failure to follow the guidelines completely and accurately may result in engine shutdown situations. Kenworth offers a variety of DEF tank sizes to meet every application. The DEF tank volume is regulated by the E.P.A. Kenworth advises against modifying the tank volume after the truck has been delivered from the factory. Total DEF capacity must meet or exceed 6% of the useable fuel capacity on the truck. The calculation to determine DEF capacity is: Minimum DEF Tank Volume = Useable Fuel Capacity (gal) x 0.06. Example: For a truck with 45 useable gallons of fuel, the equation is: DEF required = 45 x 0.06 = 2.7 gallons or more of DEF. PACCAR-approved DEF hoses are required when retrofitting for system to function properly. The use of unapproved hoses for DEF lines will void warranty and may cause engine shutdown situations. The DEF pump (or Supply Module) cannot be relocated from the DEF tank. In addition, the Medium Duty Rectangular DEF Tank that is used to meet clear back of cab requirements, cannot be relocated.

Installation Requirements and Dimensions for DEF System


When relocating any DEF system components, the locations must meet the guidelines below. Failure to comply may result in non-conformance to EPA standards and engine shutdown. DEF piping relative heights: In order to ensure proper functionality of DEF system, the height differences in the guidelines below must be followed during line routing and component placement. When relocating the components the maximum pressure DEF hose length from Supply module to Dosing Module is 3 meters (118). Maintain a minimum of 3 (76mm) clearance to shielded exhaust components when routing DEF lines to prevent possible melting. If the DEF tank is relocated, the coolant lines will need to be modified. During this process, if the tank is moved forward on the chassis (ie closer to the engine), it is necessary to remove excess coolant lines and maintain the original routing path. If the tank is moved rearward on the chassis, the additional length of the cooling line required to complete the installation must be installed in a straight section of the existing coolant routing lines. This process will minimize the change in coolant flow by minimizing changes in restrictions. Increase in restriction occurs with excessive line length and bends. Work with your local Kenworth dealer if you are unsure about the coolant line modifications.

4-3

Section 4 Exhaust & Aftertreatment

Measurement Reference Points


For all relocation procedures, the measurement points referenced in the guidelines are taken from the following specific points: Supply Module: The supply module is commonly called a pump. The measurement point on the supply module is the top of the DEF fluid pressure line. See Figure 4-1.

Figure 4-1: Measurement Location of DEF Supply Module (Pump) Dosing Module: The dosing module is commonly called an injector, this injector is located on the SCR mixing pipe which is between the DPF and SCR canister. The measurement point on the dosing module is the top of the DEF fluid pressure line. See Figure 4-2.

Figure 4-2: Measurement Location of DEF Dosing Module (Injector) The following relocation guidelines are dependent on exhaust configuration and DEF tank type and location. The Dosing Module should not need to be relocated, however if it is removed for any reason, it is critical that the module is to be reinstalled at the correct orientation. Figure 4-3 below illustrates the correct installation orientations. The angle references the vertical plane. 4-4

Section 4 Exhaust & Aftertreatment

Figure 4-3: Orientation of Dosing Module

Routing to the Dosing Module (Injector)


It is important for the function of the dosing module to ensure that the dosing module is not routed downstream of DEF lines or components. If this is unavoidable (for example on RH under exhaust systems) or Horizontal (Series) Exhaust, a routing trap must be installed. A minimum of 12 of line length must be routed below the dosing module to catch any leftover DEF when system is purged.

Figure 4-4: Routing DEF Lines and DEF Trap 4-5

Section 4 Exhaust & Aftertreatment

GENERAL EXHAUST INFORMATION


Kenworth will offer a DPF and SCR exhaust system on K270/K370 chassis in 2012, which is a Horizontal Crossover system for K270/K370 models where DPF, SCR and tailpipe are installed side by side with LH horizontal tailpipe.

Figure 4-5: Horizontal Crossover DPF and SCR with Horizontal Tailpipe

Figure 4-5.1: Top view of Horizontal Crossover DPF and SCR with Horizontal Tailpipe

4-6

Section 4 Exhaust & Aftertreatment

Figure 4-5.2: Right view of Horizontal Crossover DPF and SCR with Horizontal Tailpipe

Figure 4-5.3: Back view of Horizontal Crossover DPF and SCR with Horizontal Tailpipe

4-7

Section 5 Frame Layouts and Body Mounting


FRAME LAYOUTS
The dimensions in the frame layout section are intended to aid in layout of the chassis, and to help determine the best possible combination of fuel tanks, battery boxes, diesel particulate filter (DPF), SCR canister, and Diesel Exhaust Fluid (DEF) tank. For your application, the layouts focus on the under cab area, with appropriate dimensional information included for pertinent back of cab components. Not all optional equipment is included in this section; additional components may be placed on the rail behind components shown. The Back of Cab components are shown primarily for reference. For more specific requirements, work with your local Kenworth Dealer. Please read the instructions carefully. The following dimensions are consistent across the entire section to aid in the comparison of one layout option versus another.

The visual index that follows will give you a quick overview of the layout that is included.

Visual Index
Table 5-1 Symbols

Symbol

Description Horizontal Crossover DPF/SCR

Batt

Battery Box

Air Dryer
D E F

DEF Tank

Fuel

Fuel Tank

5-1

S e c t Acronyms Index i are defined here to help you decode Throughout the Frame Layout section you will see these acronyms. They the layouts. o BOC - Back Of Cab LHUC - Left Hand under Cab n
CBOC - Clear Back of Cab RHUC - Right Hand under Cab DEF - Diesel Exhaust Fluid SOC - Side Of Cab DSOC - Dual Side Of Cab

Section 5 Frame Layouts and Body Mounting

3 D i m e n s i o n s RH BOC rectangular fuel tank, RH BOC recFigure 5-1: Horizontal Crossover DPF/SCR, LH horizontal tailpipe,
tangular DEF tank and LH BOC battery box

5-2

Section 5 Frame Layouts and Body Mounting


CRITICAL CLEARANCES Rear Wheels and Cab CAUTION: Insufficient clearance between
rear tires and body structure could cause damage to the body during suspension movement. Allow at least 8 inches clearance (See Figure 5-2.)

Normal suspension movement could cause contact between the tires and the body. To prevent this, mount the body so that the minimum clearance between the top of the tire and the bottom of the body is 8 inches (203 mm). This should be measured with the body empty. See Figure 5-2.

Figure 5-2. Minimum Clearance Between Top Of Rear Tires And Body Structure Overhang.

CAUTION: Maintain adequate clearance between back of cab


body. See Figure 5-2.

and the front (leading edge) of mounted

Note: Be sure to provide maintenance access to battery box and fuel tank ll neck.
The true distance from the centerline of the front axle to the back of the cab is 13.3 inches (337.8mm) for K270 and 11 inches for K370 (279.4 mm). It is recommended that the leading edge of the body be mounted a minimum of 4 inches (102 mm) behind the cab. The result is a minimum backofcab clearance of 17.3 for K270 and 15 inches for K370 (381 mm) from the front axle to the leading edge of the body (A). See SECTION 3 DIMENSIONS for further details on dimensions and clearances. Also, see APPENDIX B WEIGHT DISTRIBUTION for explanation of backofcab (BOC)/CA calculations.

Figure 5-3. Minimum Back of Cab Clearance 5-3

Section 5 Frame Layouts and Body Mounting

S e c t the rail could fail prematurely and cause an WARNING: If the frame rail anges are modied or damaged, i DO accident. When mounting a body to the chassis, NOT drill holes in the upper or lower ange of the frame rail. Mount the body using body mounting brackets or Ubolts. o n

Body Mounting Using Brackets

3 D and the top ange of the frame rail. Failure CAUTION: Always install a spacer between the body subframe to do so could result in corrosion due to dissimilar materials. i m Installation of a spacer between the body subframe and the top ange of the frame rail will help prevent premature e wear of the components due to chang or corrosion. n Frame Sill s the frame sill spacer be made from a strip of If the body is mounted to the frame with brackets, we recommend that rubber or plastic (delrin or nylon). These materials will not undergo large i dimensional changes during periods of high or low humidity. The strip will be less likely to fall out during extreme relative motion between body and chassis. o See Figure 5-4. n s

5-4

Section 5 Frame Layouts and Body Mounting


Body Subframe (Rail) Spacer Chassis Frame (Rail) Sill

Figure 5-4. Spacer Between Frame Sill and Body Rail - Rubber or Plastic

Brackets
When mounting a body to the chassis with brackets, we recommend designs that offer limited amount of relative movement, bolted securely but not too rigid. Brackets should allow for slight movement between the body and the chassis.
For instance, Figure 55 shows a high compression spring between the bolt and the bracket.

Figure 5-5. High Compression Spring Between the Mounting Bolt and Upper Bracket

Figure 5-6. Rubber Spacer Between Brackets

Another possibility is mounting a rubber spacer between the brackets. See Figure 5-6. These designs will allow relative movement between the body and the chassis during extreme frame racking situations. Extreme frame racking and mountings that are too rigid, could cause damage to the body. This is particularly true with tanker installations.

Mounting Holes
When installing the lower bracket on frame rails the mounting holes in the chassis frame bracket and frame rail must comply with the general spacing and location guidelines illustrated in Figure 5-7. The hole diameter should not exceed the bolt diameter by more than .060 inches (1.5 mm).

Upper Frame Flange Lower Frame Flange

A or B Equal to or Greater Than 2 Inches (50 mm)

Figure 5-7. Hole Locations Guidelines for Frame Rail and Bracket A 5-5

Section 5 Frame Layouts and Body Mounting

Figure 5-8. Crossmember-Gusset Hole Pattern Requirements. [inch(mm)]

Frame Drilling WARNING: When mounting a body to the chassis, DO NOT drill holes in the
upper or lower flange of the frame rail. If the frame rail flanges are modified or damaged, the rail could fail prematurely and cause an accident. Mount the body using body mounting brackets or Ubolts.

WARNING: Use care WARNING:

when drilling the frame web so the wires and air lines routed inside the rail are not damaged, Failure to do so could cause an inoperable electrical or air system circuit. Do not drill new holes any closer than 2 inches (50 mm) to existing holes. Frame drilling affects the strength of the rails.

Hole Location Guidelines


Holes must be located from the ange as indicated in Figure 5-7. They must be no closer than 2 inches (50 mm) to each other.

Note:

If your design permits placement of body mounting brackets at crossmember locations, you can use the crossmember gusset bolt holes for body mounting. See Figure 5-8

BODY MOUNTING USING UBOLTS Spacers


If the body is mounted to the frame with Ubolts, use a hardwood sill [minimum 1/2 inch (12 mm) thick] between the frame rail and body frame to protect the top surface of the rail ange.

5-6

Section 5 Frame Layouts and Body Mounting


WARNING!
Do not allow the frame rails or anges to deform when tightening the Ubolts. It will weaken the frame and could cause an accident. Use suitable spacers made of steel or hardwood on the inside of the frame rail to prevent collapse of the frame anges.

Use a hardwood spacer between the bottom ange and the Ubolt to prevent the Ubolt from notching the frame ange. See Figure 5-9.

Body Structure

U-Bolt

Wood Sill 0.5 (12mm) Minimum

Truck Frame U-Bolt Spacer (Hardwood) Frame Rail Spacer (Fabricated Steel or Hardwood) Figure 5-9. Acceptable U-Bolt Mounting with Wood and Fabricated Spacers

WARNING!

Do not allow spacers and other body mounting parts to interfere with brake lines, fuel lines, or wiring harnesses routed inside the frame rail. Crimped or damaged brake lines, fuel lines, or wiring could result in loss of braking, fuel leaks, electrical overload or a re. Carefully inspect the installation to ensure adequate clearances for air brake lines, fuel lines, and wiring. See Figure 510. Mount Ubolts so they do not chafe on frame rail. Failure to do so could result in premature wear of the U-bolt or frame rail.

CAUTION:

Frame Rail Air Lines and Wiring Harness Check Clearance Space for Air Lines and Wiring

U-Bolt Frame Rail Spacer (Hardwood or Steel U-Bolt Spacer

Figure 5-10. Clearance Space for Air Lines and Cables

5-7

Section 5 Frame Layouts and Body Mounting


WARNING!
Do not notch frame rail anges to force a Ubolt t. Notched or damaged frame anges could result in premature frame failure. Use a larger size Ubolt. Use a hardwood spacer as shown in Figure 5-9.

REAR BODY MOUNT


When Ubolts are used to mount a body, we recommend that the last body attachment be made with a shplate bracket. See Figure 5-11. This provides a rm attaching point and helps prevent any relative fore or aft movement between the body and frame.

Body Structure

Frame Rail

Figure 5-11 Example of Fishplate Bracket at Rear End of Body, used with U-Bolts 5-8

Section 6 Frame Modications


FRAME MODIFICATIONS Introduction
The K270/K370 offers customer specied wheelbases, so, in most cases frame modications to produce a certain wheelbase should not be necessary. However, some installations may require slight modications, while other installations will require extensive modications. Sometimes an existing dealer stock chassis may need to have the wheelbase changed to better t a customers application. The modications may be as simple as shortening or lengthening the frame cutoff, or they may be as complex as changing the wheelbase.

DRILLING RAILS Location and Hole Pattern


If holes need to be drilled to attach anything to the rail, see SECTION 5 BODY MOUNTING for more information. Follow the general spacing and hole location guidelines. See Figure 5-7.

WARNING!

When mounting a body to the chassis, DO NOT drill holes in the upper or lower ange of the frame rail. If the frame rail anges are modied or damaged, the rail could fail prematurely and cause an accident. Mount the body using body mounting brackets or Ubolts

WARNING! CAUTION: WARNING!: CAUTION: CAUTION:

Do not drill new holes any closer than 2 inches (50 mm) to existing holes. Frame drilling affects the strength of the rails.

An appropriately sized bolt and nut must be installed and torqued properly in all unused frame holes. Failure to do so could result in frame crack initiation around the hole.

Use care when drilling the frame web so the wires and air lines routed inside the rail are not damaged, Failure to do so could cause an inoperable electrical or air system circuit.

Never use a torch to make holes in the rail. Use the appropriate diameter drill bit. Heat from a torch will affect the material properties of the frame rail and could result in frame rail cracks. Hole diameter should not exceed the bolt diameter by more than .060 inches (1.5 mm). Oversized holes could result in excessive frame wear around the hole.

Hole pattern dimensions for crossmember designs see Figure 5-8

6-1

Section 6 Frame Modications

MODIFYING FRAME LENGTH


The frame cutoff after the rear axle can be shortened to match a particular body length. Using a torch is acceptable; however, heat from a torch will affect the material characteristics of the frame rail. The affected material will normally be conned to within 1 to 2 inches (25 to 50 mm) of the ame cut and may not adversely affect the strength of the chassis or body installation.

The frame cutoff can be lengthened by adding frame extenders.

WARNING!

Do not drill new holes any closer than 2 inches (50 mm) to existing holes. Frame drilling affects the strength of the rails.

Frame Insert
A frame insert must be added after welding a frame rail extension to compensate for lost strength. The insert should be of the same material as the frame member, or of steel, and at least equal to the frame rail in thickness. Attachment of the insert to the frame should be made with Ream-Fit heat-treated bolts, 5/8 in. (16 mm) dia. or the next larger size. Both the reinforcement and frame holes should be reamed to provide a t of from .001 in. to .003 in. (.025 to .076 mm) clearance. Do not weld reinforcing members. The insert should span a distance of at least 24 in. (610 mm) on either side of the crack to insure an even distribution of stresses. Cut the ends of the insert at 45 as shown in Figure 6-2 unless the insert extends to the end of the frame.

Figure 6-1. Detail of Frame

Figure 6-2. Frame Insert Extension and Joint Welding

6-2

Section 6 Frame Modications


Where possible, use existing bolt holes to attach the insert to the frame. Bolt holes must not be located closer to the frame anges than the present bolt pattern. If the insert is placed in a section of the main frame where few bolts are located, additional bolts are required. Use the following guideline for locating additional bolt holes.

Changing Wheelbase
We do not recommend modifying the wheelbase. Occasionally, however, a chassis wheelbase will need to be reduced or lengthened. When this needs to be done there are a few guidelines that should to be considered.

WARNING! WARNING!

When changing the wheelbase, be sure to follow the driveline manufacturers recommendations for driveline length or angle changes. Incorrectly modied drivelines can fail prematurely due to excessive vibration. This can cause an accident. When changing the wheelbase, a continuous blank frame insert/outsert must be added in the area of the new rear suspension mounting bolts. All new mounting holes must pass through the original rail and the insert/outsert. Failure to do so could cause excessive stress in the original rail due to additional holes.

Before changing the wheelbase, the driveline angles of the proposed wheelbase need to be examined to ensure that no harmful vibrations are created. Consult the driveline manufacturer for appropriate recommendations.

WARNING!

Do not drill new holes any closer than 2 inches (50 mm) to existing holes. Frame drilling affects the strength of the rails.

Before the rear suspension is relocated, check the new location of the spring hanger brackets. The new holes for the spring hanger brackets must not overlap existing holes and should not come any closer than 2 inches (50 mm) to existing holes in the frame.

WARNING! When

relocating a suspension bracket, do not mount it on the extended (added) section of a frame rail. The suspension loading could result in premature failure of the added section splice. This could cause an accident. Use care when planning the wheelbase so that the rear suspension bracket is always mounted on the original rail section. See Figure 6-3.

If you are extending the wheelbase, you may also have to extend the frame length to accommodate a body. When you reposition the rear suspension spring hangers, do not mount them on the added extended portion of the rail. The relocated rear suspension bracket should be located on the original frame rails. See Figure 6-3. When reducing the wheelbase, we recommend that the suspension be moved forward and relocated on the original rail. The rail behind the suspension can then be cut to achieve the desired frame cutoff. See Figure 6-3.

6-3

Section 6 Frame Modications


WARNING! Do not drill new holes any closer than 2 inches (50 mm) to existing
strength of the rails. Before the rear suspension is relocated, check the new location of the spring hanger brackets. The new holes for the spring hanger brackets must not overlap existing holes and should not come any closer than 2 inches (50 mm) to existing holes. Mount the suspension Brackets On the Original Rail (see frame insert section & figures 6-1 and 6-2.) holes. Frame drilling affects the

Extended Wheelbase

Do Not Mount the Suspension Bracket On the Added Frame Rail

Original Wheelbase Relocated Rear Suspension

Shortened Wheelbase Figure 6-3 Comparison of Original, Shortened, and Extended Wheelbases.

Cut Frame at Rear to Obtain Desired Cutoff

Crossmembers
After changing a wheelbase, an additional crossmember may be required to maintain the original frame strength. The maximum allowable distance between adjacent crossmembers is 60 inches (1524 mm). If the distance between adjacent crossmembers exceeds this dimension, add a crossmember between them. See Figure 6-4.

Less Than 60

Before Wheelbase is Lengthened Greater Than 60

Additional Crossmember Figure 6-4. Crossmember Added When Distance Exceeds 60 Inches (1524 mm) 6-4

Section 7 Electrical
ELECTRICAL Introduction
Electrical wiring can sometimes be very frustrating. This is especially true when adding circuits to an existing setup. Through the use of an optional body harness and additional spare circuits, we have tried to reduce the complexity associated with adding common circuits to a body installation.

Note:

The most common circuits that body builders may need are pre-connected to this optional wiring harness.

The new body related circuits can be added by connecting the added circuit wires to the appropriate wires in this harness.

ELECTRICAL CIRCUITS Capacity WARNING! Do not install an electrical circuit that requires more amperage (electrical capacity) than what is
available in the specic chassis circuit. An overloaded circuit could cause a re. Compare the amperage requirements of the new circuit to the electrical current capacity of the existing chassis circuit before adding the body or other equipment.

When adding an electrical circuit, you must know the current capacity (amperes) of each circuit. The capacity of the existing system in the chassis must be enough to power the additional circuit. The new circuit will require a certain amount of power to operate; so, the existing (battery or alternator) power source must have the capacity to provide additional power or the new circuit will not function properly. Check the current (ampere) demand of the circuit to be added. Compare it to the current capacity of the circuit you are connecting into. The current carrying capacity of the wires, controls, switches, and circuit breakers that provide current to the circuit must be equal to or greater than the demand of the added circuit otherwise these components may not work properly. See Table 71.1 and for relevant circuit information.

7-1

Section 7 Electrical
Dashboard Identification.

1 2 3 4 5 6 7

ISO diagnostic plug (powertrain) OBD diagnostic plug (cab) Radio recess Accessory plug 12V/10A Spare switch Spare switch Spare switch

8 9 10 11 12 13

Spare switch Spare switch Spare switch PTO Spare switch Dump Valve Switch (Optional)

Note: For switches 5 12, use switch part number 1435592. For switch 13, use switch part number 1425594. Both switch part
numbers are 2-position switches.

Figure 7-1. Instrument Layout

7-2

Section 7 Electrical
Data Bus Communication

Abbreviation List:
ABS-E TCM DIP-4 MTCO DCU ECM SWS VIC3 Lite Antilock Braking System Transmission Control Module Digital Instrument Pack Digital Tachograph Dosing Control Unit Engine Control Module Steering Wheel Switches Vehicle Intelligence Center 3

Figure 7-2. Data Bus Communication Architecture

7-3

Section 7 Electrical
REMOVAL AND INSTALLATION Removal and Installation, Switches
Removing switches 1. Insert a feeler gauge of approx. 1 mm (0.04 in) thick between the switch and the panel at the side of the finger-sized depression (A), until it touches the inside of the panel.

2. Remove the switch from its locked position by carefully moving the feeler gauge in the direction of the arrow (B).

3. Carefully remove the switch from the panel. In doing so, ensure that the connector lock does not catch behind the panel, causing the connector to fall behind the panel. If necessary, remove the switch from the connector. Installing switches

1.Connect the connector. 2.Insert the switch into the opening in the panel and press until you can feel it locked.

Removal and Installation, Dashboard Panels


Note: Removal and installation of the dashboard panels have indicated in the proper sequence. In order to remove each subsequent panel, the panels described in the preceding text must have been removed. Removing steering column dashboard panel 1. If necessary, remove the floor mat. 2. Using the steering column setting, move the steering wheel to its highest possible position.

7-4

Section 7 Electrical

3. Remove the attachment bolts (1) and the panel plug (2) and remove the steering column dashboard panel.

Removing lower dashboard panel, co-drivers side 1. Remove the attachment bolts from the lower dashboard panel on the co-driver's side. Remove the lower dashboard panel on the codriver's side.

Removing engine tunnel dashboard panel 1. Remove the attachment bolts (1) and panel plugs (2). Remove the engine tunnel cover panel. 2. Disconnect the 12-V power supply connector at the rear.

7-5

Section 7 Electrical
Removing instrument panel 1. Remove the attachment bolts (1) from the decorative strip (2) around the instrument panel (3).

2. Pull the fixing clamps (see arrows) which attach the decorative strip (2) to the dashboard panel carefully out of the dashboard panel. 3. Remove the attachment bolts from the instrument panel (3). 4. Remove the instrument panel (3). 5. Remove the connector from the instrument panel (3). Removing lower dashboard panel, drivers side 1. Remove the attachment bolts (1). Remove the dashboard panel.

2. Disconnect the headlamp height adjustment unit connector at the rear. 3. Remove the attachment bolts from the connector block at the rear of the dashboard panel. 4. Remove the connector block. Removing surrounding frame cover panel 1. Remove the attachment bolts (1) in the surrounding frame. 2. Take the cover panel out of the surrounding frame.

7-6

Section 7 Electrical
Removing upper cover 1. Remove the attachment bolts from the underside of the cover. 2. Tilt the cover upwards out of the upper cover panel.

Removing central console control panel 1. Remove the switches (3) from the central console control panel (5). 2. Remove the ashtray (2) from the central console control panel (5).

3. Remove the attachment bolts (1) from the central console control panel (5). 4. Remove the central console control panel (5). 5. Disconnect the cigarette lighter (4) connector. Removing dashboard panel on right-hand side 1. Remove the attachment bolts from the dashboard panel. 2. Remove the connector of the stepwell lighting door switch.

7-7

Section 7 Electrical
Removing upper dashboard panel, drivers side 1. Remove the attachment bolts (1) from the radio panel (2). 2. Remove the attachment bolts (3) from the dashboard panel. 3. Cut the cable ties that attach the wiring harnesses to the dashboard panel.

4. Remove the dashboard panel. Unhook the radio panel (2) out of the dashboard panel. 5. Disconnect the connectors of the light switch (4) and the stepwell lighting door switch. Installing upper dashboard panel, drivers side 1. Fit the connectors of the light switch (4) and the stepwell lighting door switch. 2. Fit the dashboard panel. Hook the radio panel (2) into the dashboard panel.

3. Attach any removed cable harnesses to the dashboard panel using cable ties. 4. Fit the attachment bolts (3) for the dashboard panel. 5. Fit the attachment bolts (1) of the radio panel (2) into the dashboard panel. Installing dashboard panel, right-hand side 1. Fit the connector of the stepwell lighting door switch to the right-hand side dashboard panel. 2. Fit the right-hand side dashboard panel using the attachment bolts.

7-8

Section 7 Electrical
Installing central console control panel 1. Fit the cigarette lighter (4) connector to the rear of the central console control panel (5). 2. Fit the central console control panel (5) to the dashboard. 3. Connect the switches (3) of the central console control panel (5) to the connectors. Fit the switches (3) to the central console control panel (5). 4. Attach the central console control panel (5) using the attachment bolts (1). 5. Fit the ashtray (2) into the central console control panel (5).

Installing upper cover 1. Hook the cover into the cover panel. Attach the cover to the cover panel using the attachment bolts.

Installing surrounding frame cover panel 1. Fit the cover panel into the surrounding frame using the attachment bolts (1).

7-9

Section 7 Electrical
Installing lower dashboard panel, drivers side 1. Fit the connector block to the rear of the dashboard panel using the attachment bolts. 2. Fit the connector of the headlamp height adjustment unit to the dashboard panel. 3. Fit the dashboard panel using the attachment bolts (1).

Installing instrument panel 1. Fit the instrument panel (3) connector. 2. Fit the instrument panel (3) to the dashboard panel using the attachment bolts. 3. Push the decorative strip (2) back onto the dashboard panel using the fixing clamps. Fix the decorative strip (2) to the dashboard panel using the attachment bolts (1).

Installing engine tunnel dashboard panel 1. Fit the 12-V power supply connector to the rear of the engine tunnel dashboard panel. 2. Fit the dashboard panel to the engine tunnel using the attachment bolts (1) and the panel plug (2).

7-10

Section 7 Electrical
Installing lower dashboard panel, co-drivers side 1. Fit the lower dashboard panel on the co-driver's side using the attachment bolts.

Installing steering column dashboard panel 1. Fit the steering column dashboard panel using the attachment bolts (1) and the panel plug (2).

REMOVAL AND INSTALLATION, COMPLETE DASHBOARD


Removing dashboard

7-11

Section 7 Electrical
1. Disconnect the earth lead from the battery terminal. 2. Remove the attachment bolts and panel plug (6) and remove the steering column cover panel. 3. Remove the attachment bolts (1), (2) and (3) and remove the cover panel on the co-driver's side. 4. Remove the attachment bolts (4) and the panel plugs (5) and remove the engine tunnel cover panel. Remove the12-V power supply connector. 5. Remove the attachment bolts (7) and remove the upper cover panel. 6. Open the grille. 7. Remove the attachment bolt (1). 8. Remove the protective cover by pressing the retainer (2) to one side.

9. Detach the connectors (1) from the connecting block. 10.Press the connecting block retainer (2) inside and push the whole connecting block inside.

11.Remove the cover plate (2) by releasing the retainer (1).

7-12

Section 7 Electrical

12.Remove the connectors (2). 13.Push the retainers (1) to one side and push the connector plate inside.

14.Remove the attachment bolts (1) from the filter casing and remove the filter casing (2).

15.Remove the attachment bolts (1). 16.Remove the heater hoses (2) and seal the heater tubes.

7-13

Section 7 Electrical

17.Remove the connectors to the left and right of the steering column. 18.Remove the connectors (2) and the earth connections (3). 19.Remove the attachment bolts on the underside of the dashboard, left and right. 20.Remove the attachment bolts (4) and (1). 21.Take the cover plate in the A-post out of the retainer, remove the handgrip's attachment bolt and remove the handgrip (5).

22.Remove the floor mats. Remove the diagnostic and ECAS connectors by taking the wiring apart and then removing the attachment bolts. Detach the connectors from the bracket. 23.Remove the floor pan above the wiring. 24.Remove the wiring in front of the seat. 25.Remove the attachment bolts in the surrounding frame. 26.Remove the attachment bolts on the underside and remove the complete dashboard. Installing dashboard 1. Fit the dashboard and secure it in the surrounding frame with a few attachment bolts. 2. Fit the seat wiring. 3. Replace the floor pan above the wiring. 4. Fit the ECAS and diagnostic connectors to the bracket. 5. Fit the handgrip and the cover panel in the A-post 6. Fit the connectors in the central box. 7. Remove the blocks from the coolant hoses and attach the hoses. 8. Fit the connectors to the left and right of the steering column. 9. Fit the attachment bolts (1). 10.Fit the heater hoses (2).

7-14

Section 7 Electrical

11.Fit the filter casing (2). Secure the filter casing with the attachment bolts (1).

12.Fit the plate for the connectors via the inside and press it into the retainers (2). 13.Fit the connectors (1). 14.Fit the cover plate.

15.Fit the connecting block via the inside and press it firmly into the retainers (2). 16.Fit the connectors (1) to the connecting block. Pay attention to the markings on the components. 17.Fit the protective cover to the cab feed through and secure it with the attachment bolt (1). 18.Close the grille.

7-15

Section 7 Electrical

19.Fit the attachment bolts under the dashboard to the left and right. 20.Secure the attachment bolts in the surrounding frame. 21.Fit the dashboard panels on the co-driver's side. 22.Fit the steering column dashboard panels. 23.Fit the 12-V connector to the engine tunnel dashboard panel. 24.Fit the cover panel to the engine tunnel. 25. Fit the earth lead to the battery terminal.

A Canadian option is available. The speedometer will have primary units in metric. For models K270/K370, additional gages will need to be hard wired and remotely mounted.

7-16

Section 7 Electrical

PIN 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Signal Terminal 30 Terminal 31 K-Line FLA-LOAD I-CAN-L I-CAN-L I-CAN-H I-CAN-H V-CAN-SHLD I-CAN-SHLD V-CAN-L V-CAN-L V-CAN-H V-CAN-H

Description Power Supply Ground K-line Parameter Flash Loader Call I-CAN-Low I-CAN-Low I-CAN-High I-CAN-High Res. V-CAN-Shield Res. I-CAN-Shield Vehicle CAN Low Vehicle CAN Low Vehicle CAN High Vehicle CAN High

7-17

Section 7 Electrical
Fuel Level Gauge Fuel Gauge 0 1 Coolant Level Gauge 0 20 40 60 80

Coolant Gauge 0 1 0 20 40 60 80

Diesel Exhaust Fluid Gauge

DEF Gauge 0 1 0 20 40 60 80

Air Pressure Gauge

Air Pressure Gauge 0 60 145 0 32 80

7-18

Section 7 Electrical

Speedometer, Canadian Option

Speed Gauge KM/h KM/h Angle 0 0 5 9 10 19 15 28 20 37 25 47 30 56 35 65 40 75 45 84 50 93 55 102 60 112 65 121 70 130 75 140 80 149 85 159 90 168 95 177 100 186 105 196 110 205 115 214 120 223 125 233 130 242 135 251 140 261 145 270

7-19

Section 7 Electrical

Speedometer, US option
Speed Gauge MPH MPH Angle 0 0 5 15 10 30 15 45 20 60 25 75 30 90 35 105 40 120 45 135 50 150 55 165 60 180 65 195 70 210 75 225 80 240 85 255

7-20

Section 7 Electrical

Tachometer

Tachometer RPM X 100 Angle 0 0 --6 23 7 28 8 34 9 40 10 45 11 54 12 63 13 72 14 81 15 90 16 99 17 108 18 117 19 126 20 135 21 144 22 153 23 162 24 171 25 180 26 189 27 198 28 207 29 216 30 225 31 234 32 243 33 252 34 261 35 270

Color WHITE WHITE WHITE BLACK BLACK BLACK BLACK BLACK GREEN GREEN GREEN GREEN GREEN GREEN GREEN GREEN GREEN BLACK BLACK BLACK BLACK BLACK BLACK BLUE BLUE BLUE BLUE BLUE BLUE RED RED RED

7-21

Section 7 Electrical

Power Distribution Center.

Pin C D F G B

Circuit WHIT1100-1 WHIT1100-2 RED3111-0 RED3111-1 RED1510-0

Orange Description PDC Ground PDC Ground ECM Power (12V+) ECM Power (12V+) XMSN ECU (12V+)

Pin A B C D E F G H

Circuit YEL2110-0 YEL_BLK2110-1 YEL2006-0 YEL_BLK2006-1 YEL_BLK2007-1 YEL2007-0 YEL_BLK2120-0 YEL2120-0

Grey Description DIP HL (12V+) DIP HL (24V+) LH Turn (12V+) LH Turn (24V+) RH Turn (24V+) RH Turn (12V+) Main HL (24V+) Main HL (12V+)

A F G H

RED0710-0 WHIT1100-3 WHIT1100-4 ORN3114-0

Black Heat Fuel Filter (12V+) PDC Ground PDC Ground Converter Ignition

A B C D E F G H

Brown YEL2150-0 Fog Lamp (12V+) YEL_BLK2150-1 Fog Lamp Sw (24V+) ORN1229-0 Chassis Ignition (12V+) ORN_BLK1229-2 Ignition Signal (24V+) ORN1256-0 NOX up (12V+) ORN1256-1 NOX down (12V+) YEL_BLK2155-1 Body Lamp (24V+) YEL2155-0 Body Lamp (12V+)

Green C A RED3215-0 DCU Power (12V+) D B RED3237-0 Line heat (12V+) E C ORN3912-0 Starter sol (12V+) F D ORN_BLK3912-1 Start Signal (24V+) E ORN_BLK1229-3 Ignition Signal (24V+) F ORN1229-1 Engine Ignition (12V+) G ORN3112-0 ECM w/u (12V+) H ORN3215-0 DCU w/u (12V+) The voltage converter provides 24V to cab systems. It is located inside the battery box. This voltage converter works with the Power Distribution Center (PDC) with the following characteristics: 12V Input 24V output Input Current: 80 Amps Output Current: 40 Amps Temperature range: -40C to +85C

Red YEL2601-0 Stop Lamp (12V+) YEL_BLK2601-1 Stop Lamp (24V+) YEL_BLK2169-1 Clearance (24V+) YEL2169-0 Clearance (12V+)

7-22

Section 7 Electrical
To add on a wiring from cab to chassis, it is necessary to pass over the PDC to the converter. The output voltage from cab to a chassis is 24V, but 12V is necessary. The spare circuits are described in Table 7.1, as well as the pins that can be used.

Spare Circuit Powered Through: Spare 1 Spare 2 Spare 3 Spare 4 Spare 5 Spare 6* Spare 7* Spare 8*

Minimum Wire Gauge 16 16 20 12 14 N/A N/A N/A

Pin A

Pin B

Circuit PDC Terminal 2B 2G 3H 3A 3B 3C 3D 3E

Capacity (Fuse number/Amperes). Install a fuse of appropriate rating. F20/10Amp F20/10Amp F21/5Amp F22/25Amp F23/20Amp Empty Empty Empty

Numbered connector Location PDC at battery box.

RG7 RG7 RC8 RE7 RE8 RG8 RG8 RG8

RH7 RH7 RD8 RF7 RF8 RH8 RH8 RH8

Red Connector (B068-7099-F) Red Connector (B068-7099-F) Black Connector (B068-7099-A) Black Connector (B068-7099-A) Black Connector (B068-7099-A) Black Connector (B068-7099-A) Black Connector (B068-7099-A) Black Connector (B068-7099-A)

*this connector available w/o fuse K246-746: Connector with 12 long pigtails with butt spices for use when connecting to dash harness spare connectors. K246-744: Connector with 12 long pigtails with butt spices for use when connecting to engine or chassis harness spare connectors

Table 7-1. Additional Spare Circuits for Wiring


On Power Distribution Center (chassis).

7-23

Section 7 Electrical Body Builder 9 pin connector

WIRE DESCRIPTION

FUNCTION

PIN

CIRCUIT

WIRE COLOR

CAPACITY FUSE (AMPERES NUMBER)

WIRE GAUGE

GND Stop LP

Ground Stop lamp Not Connected Not Connected Tails/Marker LP Tails / markers lamps Turn RH rear Turn signal right hand rear Backup LP Backup lamp Turn LH rear Turn signal left hand rear Clearance Clearance

R S T U V W X Y Z

WHT2400-1 YEL2601-2

YEL2422-1 YEL2007-6 YEL2960-1 YEL2006-6 YEL2412-9

White Yellow F18 / 25A Not Connected Not Connected Yellow F19 / 20A Yellow F15 / 15A Yellow TCU Relay Yellow F14 / 15A Yellow F19 / 20A

10 12

12 12 12 12 12

7-24

Section 7 Electrical
PTO Wiring The truck has a PTO installed. Harness P92-3117-0000 has the necessary connectors to install a PTO. Instructions are shown below.
Connector to Engine Harness

Connector to PTO Valve

Connector to PTO Pressure Switch

7-25

Section 7 Electrical
Remote PTO / Throttle Harness
This option provides a connection from the engine ECU to the end of the frame to fit the engine throttle remote control and PTOs. Controls are not provided. A 12-pin Deutsch connector (Deutsch P/N DT06-12SA-P012) is included. Adding Electrical Options

WARNING!
Follow the engine manufacturers guidelines for use of these circuits. See your engine manufacturer to verify that the engine is programmed correctly for the intended applications. Failure to properly program the engine or wire these circuits could cause an accident.

TERMINAL 1 2 3 4 5 6 7 8 9 10 11 12

CIRCUIT BLU3878-0 BLU3848-0 GRA5280-0 BLU3412-0 WHT3100-0 BLU3146-0 BLU3145-7 BLU3144-0 GRA4596-0 BLU3524-0 BLU3420-0 BLU3143-0

DESCRIPTION CVSG DATA Remote Engine STOP Remote Engine START CAB Lock Ground ESC N3/ SET ESC N2/ SET + ESC N1 PTO Solenoid PTO Status Remote PTO ESC Enable

7-26

Appendix A Vehicle Identication


VEHICLE IDENTIFICATION NUMBER
A 17character number (numeral and letter combination) forms the Vehicle Identication Number (VIN) which includes the Chassis Number. It contains among other information, the model year (4), assembly plant (5), and vehicle serial number (6). See Figure A1

Serial Number

Chassis Number

Figure A-1. Vehicle Identication Number (VIN).


The model year (4) is designated by an alphanumeric code in the tenth character position in the VIN. See Table A-1 and Figure A1.

Code C D E F G

Year 2012 2013 2014 2015 2016

Table A-1. Model Year (Code) Designations.

VIN Location
The VIN is marked on the Incomplete Vehicle Cer tication Label (on trucks). It is located either on the drivers door edge or door frame. See Figure A2.

Chassis Number Locations


The Chassis Number comprises the last six characters of the VIN. The K270/K370 chassis number is shown in multiple locations. Right frame rail, bottom ange (underside), about 4 to 4.5 ft. from the front end: stamped. Left frame rail, top of ange, about 4 to 4.5 feet from front end: stamped Tire, Rim, and Weight Rating Data label. Major Components and Weights label. Paint Identication label.

A-1

Appendix A Vehicle Identication


CERTIFICATION LABELS Components and Weights Label
The Major Components and Weights Label is located on either the drivers side door edge or on the door frame. See Figure A2. It includes: chassis weight and gross weight; plus, model and serial numbers for the vehicle, engine, transmission, and axles.

Tire, Rim and Weight Rating Data label

Final Stage Manufacturer Label to be Installed by Final Stage Manufacturer

Chassis Serial Number

Safety Mark (Canadian Registry Only)

Major Components and Weights Label

Incomplete Vehicle Cer tication Label Figure A-2. Locations of Cer tication Labels - Drivers Door

Figure A-2. Drivers Door and Door Frame Label

Tire/Rim and Weight Rating Data Label


The Tire/Rim and Weight Rating Data Label is located on the drivers side door edge, above the door latch. See Figure A2. It contains the following information: GVWR Gross Vehicle Weight Rating GAWR FRONT and REAR Gross Axle Weight Ratings for Front and Rear Axle TIRE/RIM SIZES AND INFLATION PRESSURES Tire/Rim Sizes and Cold Pressure Minimums Chassis (Serial) Number GVWR is the TOTAL WEIGHT the vehicle is designed to carry. This includes the weight of the empty vehicle, loading platform, occupants, fuel, and any load. Axle weight ratings are listed on the edge of the drivers door.

Note:

Incomplete Vehicle Certication Label


The Incomplete Vehicle Cer tication Label is located on the drivers side door edge below the latch. See Figure A2. It contains the following information: DATE OF MANUFACTURE VIN Vehicle Identication Number LISTING OF APPLICABLE FEDERAL MOTOR VEHICLE SAFETY STANDARDS

A-2

Appendix A Vehicle Identication

COMPONENT IDENTIFICATION
Each of the following components has their own identication label.

Engine Identication
The engine serial number is stamped on a plate located on the left front for PACCAR PX-6.

Engine Identication Location

PACCAR PX-6 Label Shown

Figure A-3. Engine Identication Location

A-3

Appendix A Vehicle Identication


Transmission Identication
The transmission identication number is stamped on a tag afxed to the right forward side of the transmission case. It includes, among other specications, the transmission model, serial, and part number.

Front Axle Identication


The front axle has an identication tag located on the front axle beam. It includes the axle model, part number and serial number.

Figure A-4. Front Axle Identication

Rear Axle Identication


The rear axle identication numbering system includes two labels or stamps. 1. Axle Housing Number Tag, located on the left forward side of the housing arm. This tag identies the axle housing. 2. Axle Differential Carrier Identication, located on the top side of the differential carrier. The following information is either stamped, or marked with a metal tag: Model No., Carrier Production Assembly No., Carrier Assembly Serial No., Gear Ratio, Axle Specications Number and OEM part number and country of origin.

2 1

Figure A-5. Rear Axle Identication

Note:

Illustrated identication tag locations are typical. Actual locations may vary by axle manufacturer and with single versus tandem axles.

A-4

Appendix B Weight Distribution


INTRODUCTION
In the Medium Duty truck market, matching the wheelbase to the body specication is extremely important. Selection of the wrong wheelbase may lead to premature component failure, poor performance, and ultimately a dissatised customer. Before selecting the proper wheelbase, it is important to have a basic understanding of weight distribution.

Abbreviations
Throughout this section, abbreviations are used to describe certain features and requirements of the vehicle (see the list below). Review this list frequently so you know what the abbreviations mean. AF BL CA = = = Frame rail overhang length behind the rear axle Body Length Back of cab to centerline of rear axle

Note:

The K270/K370 CA gures are measured from the true back of cab to the centerline of the rear axle. To obtain a usable CA the body builder must subtract any required space behind the cab, which may be needed for other equipment. = = Center of gravity: the balance point or center of a load. It is usually identied by a circle with alternating black and white quarters. Distance from the centerline of the front axle to the center of gravity of the load (L). The load can be any load such as a fuel tank, a body, or the payload. Front Axle Gross Vehicle Weight Rating Load: the weight that is carried. This could be the body, the payload or any item that has its weight distributed between the two axles. Portion of load (L) carried by front axle Portion of load (L) carried by rear axle Rear Axle Wheelbase Length

CG CGf

FA = GVWR = L = Lf Lr RA WB = = = =

B-1

Appendix B Weight Distribution


CALCULATIONS Weight Distribution without Body
There are two primary equations used in weight distribution calculations: The rst equation determines the portion of the load carried by the rear axle (Lr). Lr = CGf WB XL Portion of Load Carried by the Rear Axle Equation 1

The second determines the portion of the load carried by the front axle (Lf). Lf = L - Lr Portion of Load Carried by the Front Axle Equation 2

Note:

For the purposes of calculation, the load (L) in these equations can be either actual revenue producing load or it can be other weight that is carried such as the van body or an optional fuel tank. 100 lbs

Front Axle 100 In. 214 In. Figure B-1. Balanced Load: CGf 100 in. from front axle

Step 1. Figures B1 and

B2 show a representation of a 202 inch (5130.8 mm) wheelbase (WB) truck designed to carry a 100lb. (45.3kg) load. Figure B1 represents a truck with the load placed an equal distance between the two axles. a. For our balanced load example we need to establish the center of gravity location (CGf, as shown in Figure B1) by dividing the wheelbase by 2: CGf = b. 214 = 107 in (2717.8 mm) 2

Use equations 1 and 2 to determine the portions of the load carried by each axle. The weight distribution is calculated as illustrated below: Lr = Lf = CGf WB L - Lr XL 107 214 (100) = 50 lbs (23 kg) 100 - 50 = 50 lbs (23 kg)

Since the load is centered between both axles, 50 percent of the load is carried by each axle: i.e., 50 lb. (22.6 kg) is distributed to each axle.

B-2

Appendix B Weight Distribution


C. In Figure B2, the load (L) is located 133 in. (3378 mm) from the front axle. Moving the load towards the rear axle changes the weight distribution. Use equations 1 and 2 to determine the portion of the load carried by each axle. 100 lbs Front Axle 133 In. 214 In. Figure B-2. Unbalanced Load: CGf 133 In. From Front Axle CGf Lr = Lf = CGf WB L - Lr = XL 133 in. (3378 mm) 133 214 (100) = 62.14 lbs (28.18 kg) 100 62.14 = 38.86 lbs (17.6 kg)

The rear axle now carries a greater proportion of the load than the front axle.

Although it is usually not important to know the CG of the chassis; it is important to know the CG location of truck bodies, accessories, or loads that may be placed on the chassis. This example shows that the location of the CG of an object relative to the front and rear axles (FA and RA) affects the load carried by each axle. For most relatively uniform objects such as van bodies and fuel tanks, the CG is located close to the midpoint of the object. For nonuniform objects such as liftgates and refrigeration units, obtain the CG from the equipment manufacturer.

B-3

Appendix B Weight Distribution


Weight Distribution with Body Chassis Weights
following example, a K 2 7 0 truck is modied to include a van body mounted to the chassis. This example is a K270 chassis, 214 inches (5435.6 mm) in WB, with a standard drivetrain and fuel tank. It is a 26,000 lb. GVWR with a 8,948 lb. front axle and a 1 7 ,052 lb. rear axle.

Step 2. In the

When calculating weight distributions, start by determining chassis ground weights for each axle. The actual chassis weight will vary with the wheelbase and the options installed. Listed in Tables B-1 and B-2 are the chassis tare weights for the standard single rear axle K270 vehicles and each wheelbase conguration. We see that the 214-inch wheelbase, 2-axle K270 has the following tare weights: FA = 6263.4 RA = 9628.7 K270/K370 with nominal weights and CGs. See your Kenworth Dealer for more exact weights and CGs. It also lists their added weight when installed on the chassis and the location (from the front axle) of the CG of this added weight. Table B-1. K270/K370 Single Rear Axle Bare Chassis Tare Weights (no driver, no fuel)
Wheelbase Inches Front Rear Total

214

lb (kg) 6263.4 (2,841)

lb (kg) 9628.7 (4367.5)

lb (kg) 15892.1 (7,208.5)

Note:

The weight in Table B-1 represents an example of a standard K270 chassis.

Appendix
B-4

Appendix B Weight Distribution

Now we will calculate the distributed weight of van body that weighs 4825 pounds (2188.5 kg). Since an empty van is very close to a uniform object, you can assume that the CG of the van body is at a point equal to half of the BL.

Figure B-3. Balanced Body Unloaded: CGf 184.7 in. (4691.45 mm) from front axle. When the body is mounted on the chassis, assume that the forward edge is positioned 4 inches (102 mm) behind the back of the cab. This is equivalent to 1 7 . 3 i n c h e s ( 4 3 9 . 4 m m ) behind the front axle. Therefore, the CG of the body is located 72 inches plus half the body length from the front axle. Use Equations 1 and 2 to calculate the distributed additional weight of the body: Lr = Lf = CGf WB L - Lr XL 184.7 214 (4825) = 4164.4 lbs (1888.9 kg) 4825 4164.4 = 660.5 lbs (299.6 kg)

Adding a liftgate to the van body will present some interesting weight distribution results. We will add a 1455 pound (659.9 kg) liftgate to the end of the van body. The CG location of non-uniform objects, such as a liftgate, must be provided by the equipment manufacturer. For our example, the liftgate manufacturer has provided installation information that indicates the liftgate CGf is located 322.2 in (8183.9 mm) behind the front axle.

Rear Liftgate Example

Figure B-4. Liftgate Example: CGf 322.2 in (8183.9 mm) from front axle. B-5

Appendix B Weight Distribution


Use CGf = 246 in equations 1 and 2 to determine how the liftgate weight is distributed to the axles. CGf WB L - Lr 322.2 214 X 1455 = 2190.6 lbs (993.6 kg) 1455 - 2190.6 = -735.6 lbs (-333.6 kg)

Lr = Lf =

XL

This negative weight on the front axle illustrates the difference between the distribution of weight (L) mounted behind the rear axle versus in front of the rear axle. The load carried by the rear axle is greater than the weight of the liftgate itself. Since the weight of the liftgate (added to the vehicle) cannot be greater than 1,455 lb, the front axle loading is reduced by a compensating amount (735.6 lb). The combined weight on the front and rear axles is equal to that of the liftgate. Weight added behind the rear axle has the effect of unloading the front axle. The amount of this front axle load reduction is equal to the extra weight added to the rear axle. By positioning equipment behind the rear axle, the effective load on the rear axle is more than the weight of the equipment. The farther behind the rear axle the load is mounted, the greater the load on the rear axle. However, the combined weight, distributed to the front and rear axles (Lf plus Lr), does not exceed the weight of the liftgate.

In order to get a realistic curb weight, we add weight for a driver and fuel. For purposes of calculation, we use a standard of 200 lbs. (91 kg) for the driver. Of course, your driver weight will vary. Using CGf = 10 in equations 1 and 2: Lr = Lf = CGf WB L - Lr XL 10 214 (200) = 9.34 lbs (4.2 kg)

200 - 9.34 = 190.6 lbs (86.4 kg)

We calculate the fuel load using 7 lbs per gallon as the weight for diesel fuel. 45 gal x (7 lbs/gal) = 315 lbs (142.8 kg) Using CGf=73.9 and equations 1 and 2 for the standard tank: Lr = Lf = CGf WB L - Lr XL 73.9 214 (315) = 108.7 lbs (49.3 kg) 315 108.7 = 206.2 lbs (93.53 kg)

B-6

Appendix B Weight Distribution


COMPLETE (LOADED) VEHICLE
nal step is to put a payload in the van. Assume that the payload is evenly distributed. Freight that is distributed evenly is referred to as a water level load. Our payload total is 8,000 lb. Since it is an evenly distributed water level load, its CG location will be the same as the CG location of the van body. See Figure B 5.

Step 4. The

CGf =

1 BL + 72 2

1 (168) + 72 = 156 in. 2

Using CGf = 156 in equations 1 and 2: CGf WB L - Lr 156 214

Lr = Lf =

XL

(8,000) = 5,831 lbs (2644 kg)

8,000 5,831 = 2,169 lbs (983 kg)

Item Chassis Fuel 45 Gal Std, Tank Tare Weight Liftgate Van Body Driver Curb Weight Payload Total Ground Weight Chassis Axle Ratings

Front Axle (FA) lb (kg) 6338.3 2875 206.2 93.5 6544.5 2968.5 -735.6 -333.6 660.7 299.6 190.6 86.4 6660.2 3021.0 2169 983.8 8829.2 4004.8 8948 4058.7

Rear Axle (RA) lb (kg) 3273.8 1484.9 108.7 49.30 3382.5 1534.2 2490.6 1129.7 4164.3 1888.8 9.34 4.23 10046.74 4557.1 5831 2644.8 15877.7 7202 17052 7734.6

Total lb 9612.1 314.9 9927 1755 4825 199.9 16706.9 8000 24706.9 26000

(kg) 4359.9 142.8 4502.8 796.0 2188.5 90.71 7578.1 3628.7 11206.9 11793.4

Table B-2. K270 Weight Distribution and Chassis Rating Calculation (sample)

B-7

Appendix B Weight Distribution

K370 sample, Assume that the payload is evenly distributed. Freight that is distributed evenly is referred to as a water level load. Our payload total is 14,500 lb. Since it is an evenly distributed water level load, its CG location will be the same as the CG location of the van body. See Figure B5. 1 BL + 72 2 1 (168) + 72 = 156 in. 2

CGf =

Using CGf = 156 in equations 1 and 2: CGf WB L - Lr 156 214

Lr = Lf =

XL

(14,500) = 10,570 lbs (4794.5 kg)

14,500 10,570 = 3,929.9 lbs (1782.5 kg)

Item Chassis Fuel 45 Gal Std, Tank Tare Weight Liftgate Van Body Driver Curb Weight Payload Total Ground Weight Chassis Axle Ratings

Front Axle (FA) lb (kg) 6845.3 206.2 7051.5 -735.6 660.7 190.65 7167.25 3929.9 11097.15 12000 3104.98 93.5307 3198.51 -333.66 299.688 86.4774 3251.01 1782.57 5033.58 5443.11

Rear Axle (RA) lb (kg) 3439.2 108.7 3547.9 2490.6 4164.3 9.34 10212.14 10570 20782.14 21000 1559.995 49.30549 1609.3 1129.717 1888.895 4.236553 4632.149 4794.471 9426.62 9525.44

Total lb (kg) 10284.5 314.9 10599.4 1755 4825 199.99 17379.39 14499.9 31879.29 33000 4664.971 142.8362 4807.807 796.0546 2188.583 90.71394 7883.159 6577.044 14460.2 14968.55

Table B-2.1. K370 Weight Distribution and Chassis Rating Calculation (sample) B-8

Appendix B Weight Distribution

Weight Distribution Analysis


Step 5. The
nal step is to total all of the front and rear axle weights to ensure that the axles are not overloaded. Table B-4 shows the assembled information in an easy to read format. Compare the calculated axle ground totals against the axle weight ratings to be sure that the truck is properly specied to haul this load. From this, it is evident that the chassis is properly equipped for this job.

These calculations illustrate the importance of doing the weight distribution analysis. In some cases the addition of one component (for example, a liftgate) can produce a dramatic difference.

Body Length
Step 6. Your analysis may produce results that
indicate an overloaded axle with a total loaded chassis weight less than the GVW. This shows that you need to use a different body length for the truck. Each wheelbase can accommodate several different body lengths. However, for each wheelbase and GVW one particular body length will provide close to optimum weight distribution on both axles. a. Tables B-5 and B-6 list Recommended Body Lengths for a particular wheelbase and GVW. These body lengths provide the best weight distribution for the listed wheelbase.

Note:

These charts were generated assuming a plain van body with water level loading. Any common additions such as lift gates or refrigeration units may indicate a different wheelbase for a given body length. Also, different body styles may require a different WB for a given size.

B-9

Appendix B Weight Distribution


Table B-3. Available K270/K370 Body Lengths Wheelbase In. (mm)
142 (3606.8) 146 (3708.4) 154 (3911.6) 158 (4013.2) 166 (4216.4) 170 (4318) 178 (4521) 182 (4622.8) 190 (4826) 194 (4927.6) 202 (5130.8) 206 (5232.4) 214 (5435.6) 218 (5537.2) 226 (5740.4) 230 (5842) 238 (6045.2) 242 (6146.8)

Body Length (Ft) 26,000 GVW 33,000 GVW 16 16 17 17 18 18* 18 20 20* 20 22 22* 22 24 24* 24 26 26* 26 27 27 28 28

*For trucks built before and including 6/22/2012

Remember that water level loading assumes that the load is arranged evenly in the body (as water would be in a tank). If uneven load distribution is part of the vehicle layout, your weight distribution analysis may indicate that a different body length, deviating from the recommended length, will provide the best weight distribution.

Note:You should always perform a weight distribution

analysis to help ensure the vehicle performs properly and meets your customers expectations.

B-10

Index

A Abbreviations, dimensions Auxiliary power B Body harness Body mount, rear Body mounting Body mounting with U-bolts Brackets, body mounting C Calculations Cautions Certication label Chassis maintenance Chassis Number Chassis weight Circuits, description Clearance, air lines and wiring Critical clearances Crossmember location Crossmembers D Dimensions Dimensions, air tanks Dimensions, battery box Dimensions, crew cab, conversion Dimensions, overall E Electrical circuits Emissions requirements Engine serial number F Federal Motor Vehicle Safety Standards Final stage manufacturer Fishplate bracket Frame, drilling

3-1 6-5

Frame, welding Front axle serial number Front View Fuel tank locations G Ground clearance I Incomplete vehicle cer tication Incomplete Vehicle Cer tication Label M Mounting holes, frame N Noise Requirements Notes O Operating information Options weights R Rear axle identication Rear suspension, changing Rear View Remote PTO/throttle harness Repair information S Safety signals Scope Sill spacer Spare Circuits Step height T Transmission identication Turning radius V Vehicle Identication Number W Warnings Water level load Weight distribution Weight distribution analysis Wheelbase, changing

6-2 A-4 3-9 3-22

6-3 5-8 5-1 5-6 5-4

3-23

2-2 A-2

B-2 2-1 2-2 1-1 A-1 B-4 7-3 5-7 5-3 3-18 6-4

5-5

2-3 2-1

1-1 B-4

3-1 3-21 3-21 3-11 3-2

A-4 6-3 3-9 7-26 1-1

6-1 2-3 A-3

2-1 1-1 5-4 7-1 3-22

2-2 2-2 5-8 5-6

A-4 3-1

A-1 2-1 B-10 B-1 B-9 6-3

06/12

A DIVISION OF PACCAR
Kenworth Truck Company P.O. Box 1000 Kirkland, WA 98083 (425) 828-5000e